Title: Offline adaptive control

Authors: K.P. Karunakaran, Mihir Shah, R. Shringi, A. Bernard, P.J. Arrazola

Addresses: Rapid Manufacturing Laboratory, Department of Mechanical Engineering, Indian Institute of Technology, Bombay, Powai, Mumbai-400076, India. ' Rapid Manufacturing Laboratory, Department of Mechanical Engineering, Indian Institute of Technology, Bombay, Powai, Mumbai-400076, India. ' Department of Mechanical Engineering, Engineering College, Kota State, Rajasthan, India. ' Departement Ingenierie des Produits et Systemes Industriels de l'Ecole Centrale de Nantes, 1, rue de la Noe, BP 92101, F-44321-Nantes Cedex 03, France. ' Departamento de Fabricacion, Escuela Politecnica Superior de Mondragon Unibertsitatea, Loramendi 4, 20500 Mondragon, Spain

Abstract: CNC machining is the only option for rapid manufacturing of components with stringent quality requirements. But the bottleneck to CNC machining is the generation of fool-proof CNC programs. While the CNC programmer is able to generate the correct cutter paths using CAM systems, it is not as easy with the cutting parameters. Adaptive control is able to overcome this difficulty but it requires expensive online force measurements. An alternative is to predict the cutting forces offline from the geometry, kinematics, material properties and cutting parameters. A process model developed for this calculates the optimal cutting parameters at any instant from the contact surface between the cutter and work piece. This hybrid model captures the invariant characteristics of the process in six cutting coefficients determined through simple experiments. This model is applicable to complex machining involving the generic cutter and motions up to five degrees of freedom.

Keywords: CNC machining; high speed machining; HSM; complex machining; rapid manufacturing; process modelling; adaptive control; CNC programmming; cutting forces; cutting parameters; optimisation.

DOI: 10.1504/IJMMM.2010.036144

International Journal of Machining and Machinability of Materials, 2010 Vol.8 No.3/4, pp.356 - 371

Published online: 22 Oct 2010 *

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